3D-printable high torque servo/gear reduction
This servo/gear reduction uses mostly 3D-printed parts. The servo uses a 775 36V 9000rpm brushed DC-motor which is driven by a BTS7960B motor driver which is controlled by an Arduino mega 2560. The stall torque of the servo is about 55kg/cm which is about 5.39 Nm. the peak current is about 18 amps when using a 6s LIPO battery (about 22-24V). the reduction ratio is 1:30.
For the intend of filming the internals of the servo for possible failures, the gears were printed in different colors and a 5mm acrylic lid was laser cut. Unfortunately I didn't get to film any awesome footage of gears exploding because they were far to strong. Even at a peak torque of 54kg/cm they didn't show the slightest form of flexing or cracks.
The two middle gears (blue and red one) use a stainless steel shaft of 6mm diameter. The holes of the gears are designed at 6.2mm diameter so they would fit nicely around the 6mm shaft but some additional filing/sanding might be required. The same might has to be done for the 20mm shaft holes.
A DXF file of the lid has been uploaded so people with a laser cutter can cut the lid out of transparent acrylic.
STL-files and the Fusion 360 source files can be downloaded here: https://bbprojects.technology/stl-fusion-360-source-files/3d-printable-high-torque-servo-gear-reduction-files
The Lid DXF file can be downloaded here